Method of manufacturing a golf ball

ABSTRACT

A method of manufacturing golf balls is disclosed that prevents the cover from cracking due to thermal expansion of the core during the cover formation process. The method includes the forming a core. One or more optional boundary layers can be applied to the surface of the core. The core and any boundary layers are pre-heated such that the core and any boundary layer undergo volumetric thermal expansion. After the pre-heating, the cover of the ball is formed over the core and any boundary layer. The method of the present invention also decreases cover molding cycle times for golf balls.

CROSS REFERENCES TO RELATED APPLICATIONS

Not Applicable

S

TATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT NotApplicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to golf balls. Morespecifically, the present invention relates to methods for manufacturinggolf balls and golf balls manufactured thereby.

2. Description of the Related Art

Golf balls may comprise one-piece constructions or they may includeseveral layers including a core, one or more intermediate layers and anouter cover that surrounds any intermediate layer and the core. Inmulti-component golf balls, there exists an inner core. Often, this coreis made by winding a band of elastomeric material about a sphericalelastomeric or liquid-filled center. Alternatively, the core may be aunitary spherical core made of a suitable solid elastomeric material.One such material that is conventionally used for the core of golf ballsis a base rubber, such as polybutadiene, which is cross-linked with ametal acrylate, such as zinc diacrylate.

In the construction of some multi-component golf balls, an intermediateboundary layer is provided outside and surrounding the core. Thisintermediate boundary layer is thus disposed between the core and theouter cover of the golf ball.

Located outwardly of the core and any intermediate boundary layer is acover. The cover is typically made from any number of thermoplastic orthermosetting materials, including thermoplastic resins such asionomeric, polyester, polyetherester or polyetheramide resins;thermoplastic or thermoset polyurethanes; natural or synthetic rubberssuch as balata (natural or synthetic) or polybutadiene; or somecombination of the above.

Golf balls are typically manufactured by various molding processes,whether one-component or multicomponent balls. Generally, the core ofthe golf ball is formed by casting, compression molding, injectionmolding or the like. If an intermediate boundary layer is desired, oneor more intermediate boundary layers are added over the core by anynumber of molding operations, including casting, compression molding,and/or injection molding. The cover is then formed over the core andintermediate boundary layers, if present, through casting, compressionmolding, and/or injection molding.

One example of a conventional golf ball manufacturing process isdescribed in U.S. Pat. No. 3,068,522, issued on Dec. 18, 1962 (“the '522patent”). The manufacturing process disclosed in the '522 patent uses amolding press having upper and lower die portions that surround a golfball core. A retractable seat contacts the golf ball core to place thesame in the desired orientation within the die cavity. The covermaterial is then injected into the die cavity to form the cover of theball. The '522 patent further discloses that the timing of theretraction of the retractable seat is critical and depends, in part, onthe flow rate of the cover material into the mold cavity. In order toprevent the retardation of the flow rate or prehardening of the injectedcoating material, the '522 patent teaches that in some instances, it maybe necessary to heat the molding dies and pre-heat the golf ball core toa temperature slightly above ambient temperature.

Another example, U.S. Pat. No. 5,194,191 (“the '191 patent”), issuedMar. 16, 1993 discloses a method of preparing thread-wound golf balls.In the '191 patent, a rubber thread or material is wound around a frozencore of material to form a core. Immediately thereafter, the coreundergoes microwave heating to rapidly thaw the frozen core withoutheating the rubber thread layer and without moisture condensation takingplace on the surface of the core. The method of the '191 patentallegedly reduces the core thawing time and eliminates the need for adrying step.

These and other current golf ball manufacturing processes continue tosuffer from a number of disadvantages. For example, when the outer coverof the golf ball is made from a thermoset material, e.g., thermosetpolyurethane, the core and any intermediate boundary layer(s) tend toundergo thermal expansion during the casting of the outer cover, as heatis generated by the exothermic reaction of the thermoset processes usedin the formation of the cover. As the cover forms, and before the coverdevelops sufficient green strength, the thermal expansion of the coreand any intermediate boundary layer, in turn, may cause the outer coverof the golf ball to fracture or crack. Although this problem isparticularly relevant to covers that are formed of thermosetpolyurethane, it is not believed to be limited thereto. Similar problemsmay arise with other materials and processes.

Cracking is not the only problem with the current conventional methodsof manufacturing golf balls. Since a temperature gradient exists betweenthe core, intermediate layer, if any, and the outer cover, the centralportion of the ball acts as a heat sink that absorbs heat given offduring the cover-making process. In this regard, the reaction that takesplace to cure the outer cover takes longer given the cooler temperaturein the inner core of the ball. Production cycle times are thus adverselyincreased.

Consequently, there remains a need for methods of manufacturing golfballs that do not suffer from the above disadvantages. Moreover, themethods would preferably decrease the cycle time between productionruns.

BRIEF SUMMARY OF THE INVENTION

One aspect of the present invention is a method of manufacturing a golfball. The method generally commences with heating a golf ball precursorproduct at a predetermined temperature and for a predetermined timeperiod to achieve a predetermined volumetric thermal expansion of thegolf ball precursor product. Next, a cover is applied over the thermallyexpanded golf ball precursor product.

The method may further include forming a golf ball precursor product.The forming of the golf ball precursor product may include forming acore and applying at least one boundary layer over the core.Alternatively, the forming of a golf ball precursor product may belimited to forming a core. The predetermined temperature may be atemperature within the range of about 135° F. to about 175° F., and morespecifically a range of about 140° F. to about 160° F.

The at least one boundary layer may be a thermoplastic elastomer, andmore specifically an ionomer. The cover may be a thermoset material, andmore specifically a polyurethane thermoset material. The predeterminedtime period for heating may be about one hour at the predeterminedtemperature. The heating may be at a predetermined temperature and for apredetermined time period to achieve at least a 1.2% volumetric thermalexpansion of the golf ball precursor product. Alternatively, the heatingthe golf ball precursor product may be performed concurrently withforming the golf ball precursor product.

Another aspect of the present invention is a method of manufacturing agolf ball that includes forming a core, forming at least one boundarylayer surrounding the core, and heating the core and boundary layer. Theheating is conducted at a predetermined temperature and for apredetermined time period to achieve a predetermined volumetric thermalexpansion of the core and at least one boundary layer. After heating, acover is applied over the thermally expanded core and the at least oneboundary layer.

Yet another aspect of the present invention is a golf ball havingreduced susceptibility of cracking of a cover. The golf ball is producedin accordance with the method that includes heating a golf ballprecursor product at a predetermined temperature and for a predeterminedtime period to achieve a predetermined volumetric thermal expansion ofthe golf ball precursor product. Next, a cover is applied over thethermally expanded golf ball precursor product.

It is the primary object of the present invention to provide a methodfor forming a golf ball that does not fracture during the cover formingprocess.

It is an additional object of the present invention to provide a methodthat preheats a core of a golf ball, and optional boundary layer, priorto forming a cover for the golf ball.

It is an additional object of the present invention to provide a golfball that is formed by preheating the core of the golf ball, andoptional boundary layer, prior to forming a cover for the golf ball.

Having briefly described the present invention, the above and furtherobjects, features and advantages thereof will be recognized by thoseskilled in the pertinent art from the following detailed description ofthe invention when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

There is illustrated in FIG. 1 a perspective view of a core of a golfball.

There is illustrated in FIG. 2 a perspective view of a golf ballprecursor product having a cut-away portion to show a core encompassedby a boundary layer.

There is illustrated in FIG. 3 a perspective view of a golf ball havinga cut-away portion to show a core and a boundary layer encompassed by acover.

There is illustrated in FIG. 4 a perspective view of a golf ball havinga cut-away portion to show a core encompassed by a cover.

There is illustrated in FIG. 5 a golf ball produced by the process ofthe prior art.

There is illustrated in FIG. 6 a block diagram of the method of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

A golf ball may comprise a one-piece construction or it may includeseveral layers including a core and an outer cover surrounding the core.The outer surface of the cover of the golf ball may include one or morepigmented or non-pigmented protective coatings. The outer cover of thegolf ball is preferably made of any number of thermoplastic orthermosetting materials, including thermoplastic resins such asionomeric, polyester, polyetherester or polyetheramide resins;thermoplastic or thermoset polyurethanes; natural or synthetic rubberssuch as balata (natural or synthetic) or polybutadiene; or somecombination of the above. This list, however, is merely illustrative andshall not limit the types of materials suitable for use in the golfballs and methods of the present invention.

As described herein, the materials used in forming the golf ball, andthe construction of the golf ball so formed, are not believed to becritical to the manufacturing methods and golf balls of the presentinvention. Nevertheless, the manufacturing methods of the presentinvention are particularly suited to manufacturing multi-component solidgolf balls comprising a unitary solid rubber core, one or moreintermediate boundary layer(s) comprising thermoplastic elastomermaterial(s), and a thermoset polyurethane cover. Golf balls of this typeare described more fully in U.S. Pat. No. 6,117,024. entitled “Golf BallWith Polyurethane Cover”, which has been assigned to the assignee of thepresent application, and which is hereby incorporated by reference inits entirety. Without intending to limit the scope of the presentinvention, the following description is directed primarily to thepreferred multi-component golf ball and to methods of manufacturing thesame.

There is illustrated in FIGS. 1-4, a perspective view of golf balls atvarious stages of the golf ball fabrication process. As shown in FIG. 1,a core 20 is the initial component of a golf ball. As shown in FIG. 2,an optional boundary layer 21 may be molded over the core 20 at asubsequent stage of the golf ball fabrication process. As shown in FIG.3, a cover 22 may be molded over the boundary layer 21 and core 20.Alternatively, as shown in FIG. 4, the cover 22 may be molded over onlya core 20. Thus, a golf ball 25 of FIG. 3 has multiple layers, while agolf ball 25′ of FIG. 4 is composed of only a core 20 and cover 22.

The core 20 of the golf ball 25 or 25′ may be of any construction anduse any materials suitable for use in a golf ball. For example, andwithout limiting the scope of the present invention, the core 20 may beof wound, solid, foamed, hollow, or fluid-filled construction.

In the preferred embodiment, the golf ball core 20 is of a single solidlayer comprising a blend of a base rubber, a cross-linking agent, acuring agent, and one or more weight-adjusting and/or processing aidfillers. As the base rubber, it is preferred to use a polybutadienehaving a cis 1,4 content of above about 90%, and more preferably 98% orabove. Such materials are well known to those skilled in the art.

As the cross-linking agent, a large number of metal acrylate salts areknown to those skilled in the art. For example, metal salt diacrylates,dimethacrylates, or mono(meth)acrylates are preferred for use in thegolf ball cores 20 of the present invention, particularly preferred iszinc diacrylate. A commercial source of zinc diacrylate is SR-416,available from Sartomer Co., Inc. Other metal salt di- or mono-(meth)acrylates suitable for use in this invention include those inwhich the metal is calcium or magnesium.

Free radical initiators are used as curing agents to promotecross-linking of the base rubber and the cross-linking agent. Suitablefree radical initiators for use in the golf ball cores of the presentinvention include peroxides such as dicumyl peroxide, bis-(t-butylperoxy) diisopropyl benzene, t-butyl perbenzoate, di-t-butyl peroxide,2,5-dimethyl-2,5-di-5-butylperoxy-hexane, 1,1-di (t-butylperoxy)3,3,5-trimethyl cyclohexane, and the like.

Zinc oxide is also preferably included in the core formulation. Zincoxide is primarily used as a weight adjusting filler, but is alsobelieved to participate in the cross-linking of the other components ofthe core. Any of a number of specific gravity adjusting fillers may beincluded to obtain a preferred total weight of the core 20. Examples ofsuch fillers include tungsten and barium sulfate.

Additional processing aids such as dispersants and activators mayoptionally be included. In particular, zinc stearate may be added as anactivator.

Table 1 below provides the ranges of materials included in the preferredcore formulations of the present invention. All of the components,except the polybutadiene, are given as parts per hundred parts of thepolybutadiene.

TABLE 1 Component Preferred Range Most Preferred Range Polybutadiene 100parts 100 parts Zinc diacrylate 20-35 phr 25-30 phr Zinc oxide 0-50 phr5-15 phr Zincstearate 0-15 phr 1-10phr Peroxide 0.2-2.5 phr 0.5-1.5 phrFiller As needed As needed

The core components are preferably mixed and compression molded in aconventional manner known to those skilled in the art. In a preferredform, the finished core 20 has a diameter of about 1.35 to about 1.64inches for a golf ball 25 or 25′ having an outer diameter of 1.68inches. The core weight is preferably maintained in the range of about32 to about 40 gm. The core PGA compression is preferably maintained inthe range of about 50 to 90, and most preferably about 55 to 70.

One or more optional boundary layers 21 may be provided outside of thecore 20 and inside of the cover 22. The boundary layer 21 may compriseany number of thermoset or thermoplastic materials known to thoseskilled in the art. Preferably, ionomeric materials such as one or moreSURLYN® products available from DuPont, are used for the boundary layer21. The boundary layer 21 preferably has a uniform thickness throughoutand preferably ranges in thickness from about 0.025 inch to about 0.075inch or more. The boundary layer 21 is fabricated by any number ofprocesses, including casting, compression molding, injection molding,and the like.

As described above, existing methods for manufacturing golf balls havesuffered from the disadvantage that the cover 22 fractures or cracksduring the cover formation process due to the thermal expansion of thecore 20 and/or any boundary layer 21. As shown in FIG. 5, a golf ball 30of the prior art has a plurality of fractures or cracks 32 in its cover33 due to thermal expansion of its core and any boundary layersubsequent to formation of the cover 32. The present invention providesa novel solution to this manufacturing problem.

The preferred method of the present invention is generally illustratedin FIG. 6. The method initially involves forming the core 20 and one ormore optional boundary layers 21 of the golf ball 25 or 25′ to create agolf ball precursor product as shown in block 50. The golf ballprecursor product may be the core 20 alone, or the core 20 with one ormore boundary layers 21. The formation of the golf ball precursorproduct may be performed with conventional molding apparatuses withinthe same facility as the cover molding apparatus, or alternatively at anoff-site location. The golf ball precursor products, whether on-site oroff-site, are then transferred to a location in proximity to the covermolding apparatus. After formation of the golf ball precursor product,it is pre-heated to a predetermined temperature for a predetermined timeperiod as shown in block 52. The pre-heating is accomplished by applyingheat to the core 20 and any boundary layers 21, preferably to inducethermal expansion thereof as shown in block 54. The pre-heating of thecore 20 and boundary layers 21 may be achieved through any number ofmethods known to those skilled in the art. However, in the preferredembodiment, the core 20 and boundary layers 21 are pre-heated byconvection heating in an oven. An alternative means for heating the golfball precursor product is through use of microwave heating. In microwaveheating, as compared to convection heating, the surface heating of thegolf ball precursor products is greatly reduced if not eliminated. Thereduction in surface heating eliminates the adhesion of golf ballprecursor products to one another prior to application of the cover 22.It should further be appreciated that while the pre-heating is describedas being after core formation, the present methods also contemplateheating the core 20 both during and after the formation of the golf ballcore 20. In this manner, some of the heat that may be present orliberated in the core 20 from the core formation process may be used inthe pre-heating of the core 20.

The thermal expansion of the golf ball precursor product results in thevolume of the golf ball precursor product increasing from its initialsize to a larger subsequent size. Preferably, the core 20 and anyboundary layer 21 are pre-heated, prior to applying the cover 22, to atemperature of about 120° F. to about 175° F., and more preferablybetween about 140° F. to about 160° F. If using convection heating, thepre-heating preferably occurs for about one hour, or for such time asneeded to achieve an amount of thermal expansion prior to coverformation such that the cover will not crack, and/or to achieve adesired improvement in cover molding cycle time, as described below. Ifusing microwave heating, the predetermined time period is much less thanconvection heating. Microwave heating of a 1.60 inch golf ball precursorproduct for two minutes at a power of 700 Watts in a 0.7 cubic footmicrowave will thermally expand the golf ball precursor product by 0.001inches. Although the duration of the pre-heating is not believed to becritical, the above-mentioned preferred amount of time permitssubstantially even heating of the core 20 and any boundary layer 21, andresults in substantially steady-state thermal conditions within the core20 and any boundary layer 21.

While the temperature ranges and heating times disclosed above are thepreferred ranges and times, it should be noted that the invention is notlimited to any exact temperature or heating time. The purpose of thepre-heating is to subject the core 20 and any boundary layer 21 to anincrease in temperature to result in volumetric thermal expansion of thegolf ball precursor product. However, the temperature should be belowthe softening temperature of the materials of the golf ball precursorproduct. If a boundary layer 21 is utilized, the temperature isgenerally maintained below the softening temperature of the boundarylayer 21. The expansion may occur within any number of absolutetemperatures over any period of heating time that fall within theoperability ranges of the materials used. For example, any temperaturedifferential and heating time that causes a sufficient amount of thermalexpansion of the golf ball precursor product may be used in practicingthe present invention. The amount of thermal expansion preferred willvary depending on, at least, the cover material(s) and cover thicknessto be used for manufacturing the golf ball 25 or 25′. For example, for arelatively rigid cover material or a relatively thin cover, it ispreferable to cause a relatively larger amount of thermal expansion tothe golf ball precursor product to substantially prevent cover cracking.

The volumetric thermal expansion of the core 20 and optional boundarylayer 21 may be expressed as a percentage, according to the following:$\begin{matrix}{\left\lbrack {\frac{{Vol}_{final} - {Vol}_{initial}}{{Vol}_{initial}} \times 100} \right\rbrack \%} & (1)\end{matrix}$

where Vol_(final) is the average volume of the core 20 or the core 20and one or more boundary layers 21 at the high temperature, andVol_(initial) is the average volume of the core 20 or the core 20 andone or more boundary layers 21 at the lower, initial startingtemperature. It has been found that a volumetric expansion of at leastabout 1.2% is substantially sufficient to prevent cover cracking whenusing a thermoset polyurethane cover material in a casting process, asdescribed in U.S. Pat. No. 6,117,024 referred to above. It will beunderstood, however, that this is not intended to serve as a lower limitfor the volumetric thermal expansion of the present methods. Instead,the lower limit of volumetric thermal expansion for a given system willdepend on the materials, the golf ball construction (e.g., corediameter, boundary layer and cover thickness, etc.), and the moldingprocesses utilized in the system. Determination of this limit for agiven system is within the level of skill of those skilled in the art.

After pre-heating, the golf ball precursor products may be stored in ahopper disposed in proximity to the cover molding apparatus. The golfball precursor products are then introduced to the cover moldingapparatus for application of a cover 22 thereon as shown in block 56.The cover 22 is preferably applied while the core 20 and optionalboundary layer 21 are at an increased temperature, and most preferablyat the increased temperature obtained during the pre-heating thereof. Asdescribed above, the cover 22 may be composed of one or more of severaldifferent types of materials, and may be applied by any of severalmolding methods. In the preferred embodiment, the cover 22 is athermoset polyurethane that is applied in a cast molding process. Asmentioned previously, the curing of the polyurethane to form the coveris an exothermic reaction. After the cover 22 is applied to the golfball precursor product, the golf ball 25 or 25′ is further processed toform a finished ball as shown in block 58.

The method for manufacturing golf balls described above providesnumerous benefits. One such benefit, as described above, is that bypre-heating the core 20 and any boundary layer 21, the cracking of thecover 22 of the golf ball 25 or 25′ is substantially minimized oravoided altogether. Also, by pre-heating the core 20 and any boundarylayer 21 before forming the cover 22 of the golf ball 25 or 25′, thethermal expansion that would otherwise be present in the core and anyboundary layer 21 due to the cover forming process is reduced, as thesecomponents have already undergone thermal expansion. In addition, thepre-heating substantially prevents the core 20 and boundary layer 21from acting as a heat sink that drains heat from the cover formingprocess. This may result in decreased cover molding cycle times of asmuch as about 30%. Moreover, the pre-heating of the core 20 and anyboundary layer 21 also facilitates the de-molding of the golf ball 25 or25′ from a die.

EXAMPLES

The following examples demonstrate the efficacy of the present inventionin preventing the cracking or fracturing of golf balls, especiallymultilayer golf balls having a thermoset cover. Golf balls produced inaccordance with the U.S. Pat. No. 6,17,024 however unheated prior toapplication of the cover, exhibited cracking at the seam of the golfball. A determination was made that the exothermic reaction to form thethermoset cover was the main cause of the cracking of the golf ball.Cores with boundary layers were produced and pre-heated prior toapplication of the cover. The results of those experiments are shown inExamples One and Two.

Example One

Golf ball precursor products consisting of a compression molded corecomposed of a polybutadiene-based material with an injection moldedboundary layer composed of a blend of ionomers were measured cold, thatis prior to pre-heating. The cores each had a diameter of 1.54 inchesand a Rhiele compression of 82.5. The boundary layers had a Shore Dhardness of 65, and the diameter of the core and boundary layer was 1.63inches. The measurements for Example One are provided in Table Two. Theaverage diameter cold and the average volume cold are provided inColumns I and IV, respectively. The golf ball precursor products wereconvection heated for at least one hour at a temperature between 120° F.to about 175° F. The average diameter hot and the average volume hotwere measured for the golf ball precursor products, and thesemeasurements are provided in Columns II and V, respectively. Thepercentage increase in diameter and volume for each golf ball precursorproduct is provided in Columns III and VI, respectively. A thermosetpolyurethane cover was applied to each of the golf ball precursorproducts subsequent to the pre-heating. The weight, equatorial diameterand compression were measured for each of the covered golf balls andthose results are provided in Columns VII, VIII and IX, respectively.The covered golf balls of Example One, all of which were pre-heatedprior to application of the cover, did not experience any cracking orfracturing of the cover.

TABLE Two I II III IV V VI VII VIII Avg. Avg. Avg. Avg. Avg. Avg. WeightAvg. IX Diameter Diameter Diameter Volume Volume Volume with size withCompression Cold (in) Hot (in) increase cold Hot increase cover coverwith cover 1.644 1.654 0.64% 2.324 2.369 1.93% 46.216 1.681 107.5 1.6321.642 0.61% 2.276 2.318 1.85% 46.338 1.685 103.0 1.644 1.654 0.61% 2.3242.367 1.84% 46.087 1.681 107.5 1.634 1.644 0.61% 2.284 2.327 1.85%46.162 1.682 107.5 1.633 1.641 0.49% 2.278 2.312 1.48% 46.278 1.681109.0 1.634 1.641 0.43% 2.282 2.312 1.29% 46.342 1.684 103.5 1.635 1.6460.70% 2.286 2.335 2.13% 1.634 1.644 0.64% 2.282 2.327 1.94% 46.313 1.682103.5 1.633 1.643 0.61% 2.280 2.322 1.85% 46.283 1.681 105.0 1.642 1.6520.61% 2.316 2.358 1.84% 46.151 1.683 105.0 1.635 1.644 0.55% 2.289 2.3271.66% 46.179 1.681 104.5 1.631 1.641 0.61% 2.270 2.312 1.85% 46.3671.679 106.5 1.643 1.652 0.55% 2.320 2.358 1.65% 46.190 1.685 105.0 1.6351.646 0.70% 2.286 2.335 2.13% 46.269 1.684 105.5 1.635 1.644 0.55% 2.2862.324 1.66% 46.179 1.683 103.5 1.632 1.641 0.52% 2.276 2.312 1.57%46.569 1.685 102.0 1.630 1.637 0.43% 2.265 2.295 1.29% 46.381 1.683105.5 1.631 1.639 0.46% 2.272 2.303 1.39% 46.500 1.686 104.5

Example Two

Golf ball precursor products consisting of a compression molded corecomposed of a polybutadiene-based material with an injection moldedboundary layer composed of a blend of ionomers were measured cold, thatis prior to pre-heating. The cores each had a diameter of 1.52 inchesand a Rhiele compression of 79.35. The boundary layers each had a ShoreD hardness of 67.5, and the diameter of the core and boundary layer foreach golf ball precursor product was 1.63 inches. The measurements forExample Two are provided in Table Three. The average diameter cold andthe average volume cold are provided in Columns I and IV, respectively.The golf ball precursor products were convection heated for at least onehour at a temperature between 120° F. to about 175° F. The averagediameter hot and the average volume hot were measured for the golf ballprecursor products, and these measurements are provided in Columns IIand V, respectively. The percentage increase in diameter and volume foreach golf ball precursor product is provided in Columns III and VI,respectively. A thermoset polyurethane cover was applied to each of thegolf ball precursor products subsequent to the pre-heating. The weight,equatorial diameter and compression were measured for each of thecovered golf balls and those results are provided in Columns VII, VIIIand IX, respectively. The covered golf balls of Example One, all ofwhich were pre-heated prior to application of the cover, did notexperience any cracking or fracturing of the cover.

TABLE Three Avg. Avg. Avg. Avg. Avg. Avg. Weight Avg. Diameter DiameterDiameter Volume Volume Volume with size with Compression Cold (in) Hot(in) increase cold Hot increase cover cover with cover 1.631 1.644 0.80%2.270 2.324 2.41% 46.507 1.685 108.5  2 1.630 1.641 0.64% 2.268 2.3121.94% 46.506 1.682 110.0  3 1.631 1.642 0.67% 2.272 2.318 2.04% 46.6031.680 108.0  4 1.630 1.640 0.61% 2.268 2.310 1.85% 46.544 1.683 109.5  51.632 1.643 0.67% 2.276 2.322 2.04% 46.628 1.677 113.5  6 1.631 1.6410.61% 2.270 2.312 1.85% 46.501 1.680 108.0  7 1.630 1.639 0.58% 2.2652.305 1.76% 46.573 1.678 108.5  8 1.632 1.641 0.52% 2.276 2.312 1.57%46.640 1.679 109.5  9 1.629 1.640 0.64% 2.263 2.307 1.95% 46.574 1.677108.0 10 1.631 1.643 0.74% 2.270 2.320 2.22% 46.568 1.678 107.5 11 1.6281.638 0.61% 2.257 2.299 1.85% 46.537 1.678 109.0 12 1.628 1.640 0.74%2.257 2.307 2.23% 46.484 1.683 106.5 13 1.632 1.643 0.64% 2.276 2.3201.94% 46.655 1.681 110.5 14 1.630 1.641 0.68% 2.265 2.312 2.04% 46.4581.682 111.0 15 1.631 1.642 0.67% 2.272 2.318 2.04% 46.504 1.682 105.0 161.632 1.643 0.64% 2.276 2.320 1.94% 46.599 1.679 110.5 17 1.631 1.6410.64% 2.270 2.314 1.94% 46.505 1.680 109.5 18 1.630 1.640 0.58% 2.2682.307 1.76% 46.621 1.683 110.5

From the foregoing it is believed that those skilled in the pertinentart will recognize the meritorious advancement of this invention andwill readily understand that while the present invention has beendescribed in association with a preferred embodiment thereof, and otherembodiments illustrated in the accompanying drawings, numerous changes,modifications and substitutions of equivalents may be made thereinwithout departing from the spirit and scope of this invention which isintended to be unlimited by the foregoing except as may appear in thefollowing appended claims. Therefore, the embodiments of the inventionin which an exclusive property or privilege is claimed are defined inthe following appended claims.

We claim as our invention the following:
 1. A method of manufacturing agolf ball comprising: forming a golf ball precursor product, the golfball precursor product having a first volume; heating a golf ballprecursor product such that the golf ball precursor product undergoes apredetermined volumetric thermal expansion of the first volume to createa thermally expanded golf ball precursor product,wherin the thermallyexpanded golf ball precursor product substantially prevents cracking ofa cover upon application of the coverover the thermally expanded golfball precursor product through an exothermic reaction or heated process;and applying the cover over the thermally expanded golf ball precursorproduct through the exothermic reaction or the heated process.
 2. Themethod according to claim 1 wherein the cover is applied through anexothermic reaction.
 3. The method according to claim 1 wherein formingthe golf ball precursor product comprises forming a core and applying atleast one boundary layer over the core.
 4. The method according to claim1 wherein forming the golf ball precursor product comprises forming acore.
 5. The method according to claim 1 wherein heating the golf ballprecursor product comprises convection heating the golf ball precusorproduct at a temperature within the range of about 120° F. to about 180°F.
 6. The method according to claim 1 wherein heating the golf ballprecursor product comprises convection heating the golf ball precursorproduct at a temperature within the range of about 140° F. to about 160°F.
 7. The method according to claim 1 wherein heating the golf ballprecursor product comprises microwave heating the golf ball precursorproduct for a predetermined time period.
 8. The method according toclaim 3 wherein the at least one boundary layer comprises athermoplastic elastomer.
 9. The method according to claim 3 wherein theat least one boundary layer comprises an ionomer.
 10. The methodaccording to claim 1 wherein the cover comprises a thermoset material.11. The method according to claim 5 wherein heating the golf ballprecursor product comprises convection heating the golf ball precursorproduct for about one hour.
 12. The method according to claim 1 whereinheating the golf ball precursor product comprises convection heating thegolf ball precursor product at a temperature and for a time periodsufficient to achieve at least a 1.2% volumetric thermal expansion ofthe golf ball precursor product.
 13. The method according to claim 1wherein heating the golf ball precursor product comprises heating thegolf ball precursor product during and after forming the golf ballprecursor product.
 14. A method of manufacturing a golf ball comprising:forming a core; forming at least one boundary layer surrounding thecore; heating the core and the at least one boundary layer such that thecore and the at least one boundary layer undergo a predeterminedvolumetric thermal expansion to create a thermally expanded core and athermally expanded at least one boundary layer, wherein the thermallyexpanded core and the thermally expanded at least one boundary layersubstantially prevent cracking of a cover upon application of the coverover the thermally expanded core and the thermally expanded at least oneboundary layer through an exothermic reaction or heated process; andapplying the cover over the thermally expanded core and the thermallyexpanded at least one boundary layer through the exothermic reaction orthe heated process.
 15. The method according to claim 14 wherein heatingthe core and the at least one boundary layer comprises convectionheating the core and the at least one boundary layer to a temperaturewithin the range of about 120° F. to about 180° F.
 16. The methodaccording to claim 15 wherein heating the core and the at least oneboundary layer comprises convection heating the core and the at leastone boundary layer at temperature within the range of about 140° F. toabout 160° F.
 17. The method according to claim 15 wherein heating thecore and the at least one boundary layer comprises convection heatingthe core and the at least one boundary layer for about one hour.
 18. Themethod according to claim 14 wherein heating the core and the at leastone boundary layer comprises heating the core and the at least oneboundary layer at a temperature and for a time period sufficient toachieve at least a 1.2% volumetric thermal expansion of the core and theat least one boundary layer.
 19. The method according to claim 14wherein applying the cover comprises placing the thermally expanded coreand the thermally expanded at least one boundary layer within a moldcontaining a polyurethane prepolymer material and a curing agent, andmolding a thermosetting polyurethane cover over the core and at leastone boundary layer.
 20. The method according to claim 14 furthercomprising storing the thermally expanded core and at least one boundarylayer in a hopper prior to transfer to a cover molding apparatus.
 21. Amethod of manufacturing a golf ball comprising: compression molding acore composed of a polybutadiene material; injection molding a boundarylayer composed of an ionomer blend material around the core to form agolf ball precursor product, the golf ball precursor product having adiameter ranging from 1.630 inch to 1.644 inch; heating the golf ballprecursor product to cause a predetermined volumetric thermal expansionof the golf ball precursor product to create a thermally expanded golfball precursor product having at least a 1.29% volume increase of thegolf ball precursor product, wherein the thermally expanded golf ballprecursor product substantially prevents cracking of a thermosettingpolyurethane cover upon application of the thermosetting polyurethanecover over the thermally expanded golf ball precursor product through anexothermic reaction; and applying the thermosetting polyurethane coverto the thermally expanded golf ball precursor product through theexothermic reaction involving a polyurethane prepolymer and a curingagent.
 22. The method according to claim 21 wherein the volume increaseof the golf ball precursor product is between 1.3% and 2.41%.